Device and method for monitoring a cargo to be transported

Abstract

A device for monitoring cargo (12) to be loaded comprises at least one sensor (24) configured to detect at least one set of spatial coordinates of measuring points (28) (42), wherein the measuring points (28) are located in a spatial region encompassing the cargo (12). An evaluation unit (32) is configured to determine at least a part of a contour of the cargo (12) from the set of spatial coordinates of the measuring points (28) (44) and to perform a comparison (46) between the determined contour of the cargo (12) and at least one predetermined contour. An output unit (34) is configured to output a signal based on the result of the comparison.

Description

[0001] The invention relates to a device and a method for monitoring cargo to be loaded, in particular one or more containers, according to the preamble of claim 1 and 12 respectively.

[0002] Container handling plays a central role in cargo handling at ports. To move a container—that is, to pick it up, transport it, and set it down again—a STS crane (STS stands for Ship To Shore) or an RTG crane (RTG stands for Rubber Tyred Gantry) is typically used. The STS or RTG crane has a trolley with a container sling, also called a spreader, to which twistlocks are attached. The twistlocks are designed to engage with and be secured to the container's cornercasts. Once the spreader is attached to the cargo container using the twistlocks, it can be lifted by the trolley of the STS or RTG crane and transported to the desired position, where the container is then set down.

[0003] The most common containers are 20 feet (6.058 m) or 40 feet (12.192 m) long, and a crane spreader is typically capable of lifting a single 40-foot container or two 20-foot containers placed end-to-end. However, from their cab, crane operators often cannot reliably distinguish whether the container beneath the spreader is a single 40-foot container or two 20-foot containers. The danger lies in the possibility that the operator, due to poor or limited visibility, makes an incorrect decision and, with the spreader, only secures the outer corner casters of the two containers with twistlocks, leaving the inner corner casters unsecured. During the subsequent lifting process, the containers can become jammed or, in the worst case, fall. This results in a complex and therefore costly recovery operation.This unsafe lifting process also poses a great danger to people and machines.

[0004] Systems are known from the prior art that can detect the presence of a gap between two containers to be gripped after the spreader is placed on the containers. In this position, photoelectric sensors examine the top and side surfaces of the containers. If the sensors detect a gap, the crane operator or an automated crane system is notified that two 20-foot containers have been detected. Otherwise, a single 40-foot container is reported. A disadvantage of this method is that container detection is only possible in the spreader's target position and only if the spreader is positioned almost in the center. As soon as the spreader is shifted a few centimeters perpendicular to the container gap, the sensors that are supposed to detect the gap are no longer between the containers. This makes detection more difficult or even impossible.This may not be possible and will incorrectly report one 40-foot container as detected instead of two 20-foot containers.

[0005] It is therefore an object of the invention to improve a device and a method for monitoring cargo to be loaded, in particular one or more containers.

[0006] This problem is solved by a device and a method for monitoring cargo to be loaded, in particular one or more containers according to claim 1 and 12 respectively.

[0007] An inventive device for monitoring cargo to be loaded, in particular one or more containers, initially comprises at least one sensor, an evaluation unit, and an output unit. The sensor is configured to detect at least one set of spatial coordinates of measuring points. The measuring points lie within a spatial region encompassing the cargo. The evaluation unit is configured to determine at least a portion of the cargo's contour from the set of spatial coordinates of the measuring points and to perform a comparison between the determined cargo contour and at least one predefined contour. The output unit is configured to output a signal based on the result of the comparison.

[0008] The invention offers the advantage that a characteristic of cargo of interest can be easily and reliably checked during a loading process. In particular, it is not necessary to capture the entire contour of the cargo, but only the portion of the contour that can be compared with the predefined contour, which itself preferably represents only a part of the contour of the cargo to be loaded, for example, a longitudinal or cross-sectional area. This significantly simplifies both data acquisition and data analysis. This enables an increase in the overall operational efficiency of freight terminals, and especially container terminals, through enhanced safety in handling cargo and containers, and increased throughput in the dynamic and complex environment of container handling.

[0009] The specified contour can preferably be a part of the contour of a top surface, in particular a length, of cargo, for example, a container. The top surface of cargo is generally easy to detect, especially when the sensor is arranged above the cargo, for example, on a crane used for loading the cargo. For the purposes of the present invention, the term "contour" is to be interpreted broadly and includes not only the exact contour of cargo, for example, the typical corrugated surface structure of a shipping container, but also, for example, the length or width of a top surface of cargo.

[0010] A first predefined contour can preferably encompass part of the top surface of a single container and / or a second predefined contour can encompass part of the top surface of two containers arranged one behind the other. By comparing the detected cargo contour with the predefined contour(s), the characteristics of the cargo can be easily determined and information about the cargo can be output, thus facilitating further handling of the cargo during loading. For example, the contour of the top surface of a single container differs from the contour of the top surface of two containers arranged one behind the other in that there is a gap between the two containers. This makes it easy to distinguish whether the sensor has detected a single container or two containers arranged one behind the other.

[0011] A first predefined contour can preferably comprise part of the top surface of a 40-foot container, and / or a second predefined contour can comprise part of the top surface of a 20-foot container, and / or a third predefined contour can comprise part of the top surface of two 20-foot containers arranged one behind the other. By comparing the determined cargo contour with the predefined contour(s), the length and number of containers to be loaded can be easily determined. For example, the top surface contour of a 40-foot container differs from the top surface contour of two 20-foot containers arranged one behind the other, even if their lengths are essentially the same, in that there is a gap between the 20-foot containers.Within this gap, the contour and thus the spatial location of the measurement points detected by the sensor differs significantly from the spatial location of the measurement points detected at a comparable position on a 40-foot container. This makes it easy to distinguish whether the sensor has detected a 20-foot container, a 40-foot container, or two 20-foot containers arranged one behind the other.

[0012] The sensor can be configured as a LiDAR sensor, capable of scanning a predetermined spatial area defined by its field of view. The sensor can therefore be designed for distance measurement, for example, by measuring the travel time of light pulses emitted by the sensor. Each distance measurement allows the spatial location of, for example, a measurement point on the container's surface to be determined as spatial coordinates.

[0013] In one embodiment of the invention, the sensor can be configured as a 2D LiDAR sensor, wherein a light beam generated by a laser periodically scans a predetermined spatial region using a deflection unit. The light is reflected by objects in the spatial region (e.g., the surface of a container) and evaluated in the scanner. The angular position of the deflection unit is used to determine the angular orientation of the object, and the distance of the object from the laser scanner is calculated from the light travel time using the speed of light. With the angular and distance data, the location of an object in the spatial region is captured in two-dimensional polar coordinates. This allows the positions of objects to be determined or their contours to be defined.A 2D LiDAR sensor can determine the contour of cargo along a line, which is sufficient for a variety of applications, such as distinguishing a 40-foot container from two 20-foot containers placed one behind the other, as described above. In particular, the distance between two containers can also be determined. This information is necessary, for example, for correct positioning when loading containers onto a truck trailer.

[0014] In an alternative embodiment of the invention, the sensor can be configured as a 3D LiDAR sensor, in which relative movement in the transverse direction is also detected, for example, by an additional degree of freedom of the deflection unit in the laser scanner. This allows the contour of the cargo to be determined along several spatially spaced lines. This enables redundant evaluation and thus more accurate results in determining the cargo's contour. Furthermore, a 3D LiDAR sensor can be configured to completely capture the top surface of the cargo. In the case of cargo consisting of two containers, this also allows for the detection of lateral displacement of the containers relative to each other, i.e., displacement perpendicular to the longitudinal axis of the containers.

[0015] The sensor can preferably be mounted on a spreader, a lifting device on a crane used to pick up cargo. The sensor can then detect the contour of the cargo's top surface as the spreader is lowered onto it. Typical LiDAR sensors have a field of view of more than 180 degrees, so that the entire top surface of the cargo can usually be captured until the spreader rests on it. The signal output by the display unit can include information for adjusting the spreader. For example, if the cargo consists of one or more containers, the information can include the number and size of the containers, or information about which twistlocks on the spreader need to be activated to securely fasten the container(s). Furthermore, the information can include the spreader's position relative to the cargo.

[0016] The output unit can preferably be configured to transmit the signal to a crane operator, for example via appropriate display elements or voice output. The operator is then able to correctly adjust the spreader to the corresponding load based on the displayed information. Alternatively or additionally, the output unit can be configured to transmit the signal to a crane control system, for example in the case of an automated crane, and may also transmit the information to an operator for monitoring the automated crane.

[0017] According to another embodiment, the evaluation unit can be configured to determine the distance of the cargo to the spreader from the set of spatial coordinates of the measuring points, and the output unit can be configured to output the determined distance to an operator and / or to a crane control system. This allows the cargo to be approached efficiently with the spreader; for example, the approach speed of the spreader can be adjusted to the distance to the cargo.

[0018] According to a further embodiment, the evaluation unit can be configured to determine, in particular a longitudinal, offset of the load to the spreader from the set of spatial coordinates of the measuring points, and the output unit can be configured to output the offset to an operator and / or to a crane control system. This allows the position of the spreader relative to the load to be adjusted as it approaches the load.

[0019] According to another embodiment, the evaluation unit can be configured to use "prior knowledge" regarding the cargo, for example, relating to a predefined spatial area of ​​the cargo or its spatial position, when determining the cargo's contour. Such "prior knowledge" can reduce the amount of data that the evaluation unit has to process. This can reduce the computational effort required to operate the device. Furthermore, the processing speed can be increased.

[0020] According to a further embodiment, the evaluation unit can be configured to determine an angle between the top of the cargo and a lifting platform, where the cargo is lifted by the crane, from the set of spatial coordinates of the measuring points. The output unit can be configured to output the determined angle to an operator and / or to a crane control system. This allows verification during lifting of the cargo as to whether it is correctly secured to the spreader. For example, if the twistlocks of the spreader were incorrectly not locked at one end of a container, the crane would only lift the container at that end, causing the angle between the top of the container and the lifting platform to change during the lifting process. The evaluation unit would detect this change in angle.By providing information about the angle change to the operator or the crane control system, the lifting process can be stopped early if, for example, the angle change exceeds a predetermined value, thus preventing damage to the cargo or the crane.

[0021] The evaluation unit can be part of the sensor or part of an external control unit, which may also include the output unit. The predefined contour(s) of the cargo can preferably be stored in a memory unit of the evaluation unit.

[0022] The sensor can include an inertial measurement unit (IMU), and the evaluation unit can be configured to receive data from the IMU and detect sensor movement, particularly relative to the typically stationary cargo. Knowing the sensor movement allows multiple sets of spatial coordinates acquired by the sensor to be summed, thus improving the robustness of the contour determination.

[0023] The sensor can be designed as a so-called solid-state lidar without mechanically moving components for beam deflection. Such a sensor is particularly robust and can have a longer service life, especially in harsh working environments, than a conventional lidar sensor with a rotating scanning unit.

[0024] A further aspect of the invention is a method for monitoring cargo to be loaded, in particular one or more containers. According to the method, at least one set of spatial coordinates of measuring points is acquired by means of a sensor. The measuring points lie within a spatial region encompassing the cargo. From the set of spatial coordinates of the measuring points, at least a portion of the cargo's contour is determined, for example, by segmenting and clustering the measuring points acquired by the sensor. Subsequently, a comparison is performed between the determined cargo contour and at least one predefined cargo contour, and a signal based on the result of the comparison is output.

[0025] The device described above is therefore designed to execute the steps of the method by means of the sensor, the evaluation unit, and the output unit. The aforementioned embodiments of the device according to the invention thus also apply to the method according to the invention, in particular with regard to the disclosure, the advantages, and the preferred embodiments.

[0026] The invention is further explained below with regard to additional features and advantages by way of example embodiments and with reference to the accompanying drawing. The illustrations in the drawing show: Figure 1 shows a schematic representation of a crane with a device according to the invention for monitoring cargo to be loaded. Figure 2 shows an exemplary flowchart of a method according to the invention for monitoring cargo to be loaded. Figure 3 shows a schematic representation of an embodiment in which the device according to the invention is configured to determine at least one angle between the top of the cargo and a lifting point.

[0027] Figure 1Figure 10 shows a schematic representation of a crane 10 designed for loading cargo 12, for example, containers 14. For this purpose, the crane 10 includes a trolley 16 to which a spreader 18 with twistlocks 20 is attached for lifting, moving, and setting down the cargo. The crane 10 is, for example, an STS crane (STS stands for Ship To Shore) or an RTG crane (RTG stands for Rubber Tyred Gantry), as are typically used in modern port facilities.

[0028] A device 22 according to the invention, comprising a sensor 24 designed as a LiDAR sensor, is attached to the spreader 18. The sensor 24 therefore has a laser scanner that detects a certain spatial area on the top surface 26 of the containers 14. The sensor 24 is further configured to detect a set of spatial coordinates of measuring points 28 from the field of view 30 of the sensor 24, i.e., on the top surface 26 of the containers 14.

[0029] The sensor 24 is connected to an evaluation unit 32. The connection can be wired or wireless. The evaluation unit 32 is designed to determine at least part of a contour of the cargo 12 from the set of spatial coordinates of the measuring points 28 and to perform a comparison between the determined contour of the cargo and at least one predefined contour of the cargo 12.

[0030] An output unit 34 is configured to output a signal based on a result of the comparison, for example to an operator and / or a control system of the crane (not shown).

[0031] Figure 2 shows an exemplary flowchart 40 of a method according to the invention for monitoring cargo 12 to be loaded.

[0032] In a first step, at least one set of spatial coordinates of measuring points 28, which lie in a spatial area that includes the cargo, is recorded by means of a sensor 24.

[0033] In a subsequent second step, at least a part of a contour of the cargo 12 is determined from the set of spatial coordinates of the measuring points 28, for example using segmentation and clustering methods known from image processing.

[0034] In a third step, a comparison 46 of the determined contour of the cargo 12 is made with at least one predefined contour of the cargo 12, for example a check to see if the determined contour corresponds to the predefined contour of one or two containers, or if a length of a container corresponds to the length of a 20 foot container or the length of a 40 foot container.

[0035] In a further fourth step, a signal (48) is output, which is based on the result of the comparison, for example, information on whether the cargo is a 20-foot container, a 40-foot container, or two 20-foot containers. Based on this information, an operator or the crane's control system can adjust the spreader settings.

[0036] Figure 3 Figure 1 shows a schematic representation of an embodiment in which the evaluation unit of the device 22 according to the invention is designed to determine at least one angle 50 between the top surface 26 of the cargo, in this case one or more containers 14, and a lifting area 52 into which the cargo is lifted by the crane.

[0037] In a), the container 14 is attached to the twistlocks 20 of the spreader 18 in order to be lifted in lifting position 52. The angle 50 between the top surface 26 of the container 14 and the lifting position 50 is approximately 90 degrees with a certain tolerance; thus, the top surface 26 of the container 14 and the lifting position 50 form a substantially right angle 50.

[0038] Figure b) illustrates a situation in which container 14 is not attached to the spreader on one side because, among other things, a twistlock 20a is not properly locked. As a result, container 14 is only lifted on one side, causing the angle 50 between the lifting point 52 and the top 26 of container 14 to change during lifting. The device's evaluation unit can detect this change in angle and, by transmitting this information to a crane operator or crane control system, can stop the lifting process early and prevent damage to the cargo or the crane.

[0039] In c), two containers 14 are attached to the twistlocks 20 of the spreader 18 in order to be lifted in lifting direction 52. The angle 50 between the top surface 26 of the containers 14 and the lifting direction 50 is approximately 90 degrees with a certain tolerance; thus, the top surface 26 of the container 14 and the lifting direction 50 form a substantially right angle 50.

[0040] Figure d) illustrates an example situation in which the containers 14 are not attached to the spreader 18 in the middle. As a result, the containers 14 are lifted only on one side, and the angle 50 between the lifting point 52 and the top surface 26 of each container 14 changes during lifting. The evaluation unit of the device 22 can detect this change in angle, and by transmitting this information to a crane operator or crane control system, the lifting process can be stopped early, thus preventing damage to the cargo or the crane. Additionally, in this case, the contour of the surface of the cargo 12 (consisting of the two containers 14) as detected by the device 22 also changes. A corresponding error pattern can, for example, be stored as a predefined contour in the evaluation unit.If a corresponding contour is detected by the evaluation unit, an error signal can be output. Reference symbol list

[0041] 10 Crane 12 Cargo 14 Container 16 Trolley 18 Spreader 20, 20a Twistlock 22 Device 24 Sensor 26 Top 28 Measuring point 30 Viewing area 32 Evaluation unit 34 Output unit 40 Flowchart 42 Capture 44 Determine 46 Comparison 48 Output 50 Angle 52 Lifting correction

Claims

1. Device (22) for monitoring cargo (12) to be loaded, in particular one or more containers (14), comprising: at least one sensor (24) configured to detect at least one set of spatial coordinates of measuring points (28), wherein the measuring points (28) are located in a spatial area encompassing the cargo (12), an evaluation unit (32) configured to: determine at least a part of a contour of the cargo (12) from the set of spatial coordinates of the measuring points (28) and to perform a comparison between the determined contour of the cargo (12) and at least one predetermined contour, and an output unit (34) configured to output a signal based on a result of the comparison.

2. Device (22) according to claim 1, wherein the predetermined contour comprises a top surface of a cargo.

3. Device (22) according to one of the preceding claims, wherein a first predetermined contour comprises a top surface of a single container, and / or a second predetermined contour comprises a top surface of two containers arranged one behind the other.

4. Device (22) according to claim 1 or 2, wherein a first predetermined contour comprises a top surface of a 40 foot container, and / or a second predetermined contour comprises a top surface of a 20 foot container and / or a third predetermined contour comprises a top surface of two 20 foot containers arranged one behind the other.

5. Device (22) according to one of the preceding claims, wherein the sensor (24) is designed as a 2D LiDAR sensor:

6. Device (22) according to one of claims 1 to 4, wherein the sensor (24) is designed as a 3D-LIDAR sensor.

7. Device (22) according to one of the preceding claims, wherein the sensor (24) is attached to a spreader (18) of a crane (10) which is intended for picking up the cargo (12).

8. Device (22) according to claim 7, wherein the signal comprises information for setting the spreader (18) and the output unit (34) is configured to output the signal to an operator and / or to a control of the crane (10).

9. Device (22) according to claim 7, wherein the evaluation unit (32) is configured to determine a distance of the cargo (12) to the spreader (18) from the set of spatial coordinates of the measuring points (28), and the output unit (34) is configured to output the distance to an operator and / or to a control of the crane (10).

10. Device (22) according to claim 7, wherein the evaluation unit (32) is configured to determine a longitudinal offset of the cargo (12) to the spreader (18) from the set of spatial coordinates of the measuring points (28), and the output unit (34) is configured to output the longitudinal offset to an operator and / or to a control of the crane (10).

11. Device (22) according to claim 7, wherein the evaluation unit (32) is configured to determine an angle (50) between the top (26) of the cargo (12) and a lifting position (52) in which the cargo (12) is lifted by the crane (10) from the set of spatial coordinates of the measuring points (28), and the output unit (34) is configured to output the determined angle (50) to an operator and / or to a control of the crane (10).

12. Method (40) for monitoring cargo (12) to be loaded, in particular one or more containers (14), wherein the method (40) comprises the following steps: - Acquiring (42) at least one set of spatial coordinates of measuring points (28) by means of a sensor (24), wherein the measuring points (28) are located in a spatial area encompassing the cargo (12), - Determining (44) at least a part of a contour of the cargo (12) from the set of spatial coordinates of the measuring points (28), - Comparing (46) the determined contour of the cargo (12) with at least one predetermined contour, and - Outputting (48) a signal based on a result of the comparison.

13. Method (40) according to claim 12, wherein the predetermined contour comprises a top surface of a cargo.

14. Method (40) according to one of claims 12 or 13, wherein a first predetermined contour comprises a top surface of a single container, and / or a second predetermined contour comprises a top surface of two containers arranged one behind the other.

15. Method (40) according to one of claims 12 or 13, wherein a first predetermined contour comprises a top surface of a 40 foot container, and / or a second predetermined contour comprises a top surface of a 20 foot container and / or a third predetermined contour comprises a top surface of two 20 foot containers arranged one behind the other.

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